Welding is one of the most commonly used methods of joining metals for structural applications in construction and automation. Many different types of welding processes exist, ranging from spot welding to furnace brazing and even arc welding. Of these, arc welding is the most widely used. In arc welding, an electric-arc is generated between the metal and a welding rod, creating a molten pool and ultimately a welded joint. In addition to the electric-arc, filler metals such as copper, aluminum and stainless steel can be added to the weld to increase its strength and corrosion-resistance. The mechanical properties of the welds created by these procedures can be greatly affected by the welding process chosen and the quality of the materials used.
In order to analyze the effect of the welding process and the materials used on the mechanical properties of the weld, several tests were conducted on steel welds with a flux brazing electrode. First, the creation of the weld was done using a MAG (Metal Active Gas) welding process. The welds created in the test were then inspected for uniformity, weld penetration, and presence of oxide inclusions. Once the tests were completed, the welds were subjected to microhardness testing to quantify their strength. Based on the results, it was determined that the microhardness of the weld was slightly higher when using a flux brazing electrode than when using a MAG welding rod.
The welders then conducted several tensile tests on the welds. During these tests, a load of 100lbs was applied to the weld and then released to measure its yield strength, ultimate tensile strength, and ductility. The welds created by flux brazing were found to be slightly stronger than those created by the MAG welding process. The ductility of the welds was also higher when created with the flux brazing electrode.
Several types of fatigue tests were also conducted on the welds. These tests were conducted by applying loads of different magnitudes to the welds at regular intervals and measuring the fatigue life. The results indicated that the welds created using the flux brazing electrode had a longer fatigue life than those created using the MAG welding rod.
Based on these tests, it can be seen that utilizing a flux brazing electrode during welding steel can yield welds with improved mechanical properties compared to those produced by other welding processes. The improved microhardness, yield strength, ultimate tensile strength, and fatigue life improve the performance of the weld in a variety of applications. It should also be noted that the use of flux brazing electrodes often allows the welder to better control the welding process, creating welds with better penetration and fewer flaws. As such, when considering a welding process for joining steel, flux brazing is an excellent choice that can yield welds with superior mechanical performance.
